Solar powered 12v, USB, 110vac and a VHF/UHF radio

[WSS]

The top panel is ready for cerakote. Going to do it in titanium, it's a lighter gray like the pelican.

Here is the rubber bumper hold down stetup, should work great and will enable fast pull out of entire module.

The aluminum mounts that are vertical will have nylon web and fastek buckles threaded in the slots to hold solar panels down. There are two 20w panels (I can add another if needed)

Back side of top panel:

roughly finished and fit checked, holes drilled/tapped 8-32:

 

[WSS]

BAM!!! You got it! Glad you added the center support. Find you some acorn nuts for securing the top panel or use those points to secure your rubber bumpers. You will thank me later when you notice you scrape then every once in awhile.

How did you do your cut outs for the mounts? Looks like you corner drilled them and then used something to cut them.

Gotcha on the Acorn nuts. Plus they look cool.

The panels were cut on my CNC plasma table. I have a full fab shop to maintain my Automated weld company, the bonus is I get to play with some cool tools.

 

[WSS]

Got a lot done today. My hope was to finish but it is bigger than I had hoped. More detail, better results too.

Did the top panel in titanium cerakote this morning

Found these in the mailbox!!

Spent a few hours making harnesses:

 

[WSS]

Used a 12 pin duetsch connector to link to and bottom panel. All the parts are in, so just time. I will label the ports/plugs/switchs/fuses using our Dymo tape label maker. The labels are made of polyester so they are durable. Once the two panels are linked/wired, we will work on the solar connections and the 12v charger.

WSS

 

[WSS]

I'm going to attach these photos direct and not use photobucket, they are getting weird. I think my email was hacked through them.

So, it's 99% done! Tomorrow I will wire up solar panels and 12vdc charger. All works as planned and is very modular. Should last a lifetime. Maybe next battery(s) will be lifep04 or something light and expensive LOL

WSS

 

[john61ct]

Very nice.

If you were to make these in say batches of 10, what would you need to charge to get say $50 / hr for your time and 30% markup on components?

 

[WSS]

Very nice.

If you were to make these in say batches of 10, what would you need to charge to get say $50 / hr for your time and 30% markup on components?

It would be a total loss, not one would sell. LOL If it was not a summer project for my son and I, it would not have happened. The radio was free, except the separation kit, antenna, antenna mount, bulheads, etc. That saved $500, My preference would be a Yaesu FTM-400XDR. I would imagine parts were around $600 (Pelican was already on hand). We probably have 30hrs between us on it ($1500!!). Ya, so loss but great project.

In production, (of 10 like you mentioned), we could probably do them in 10hrs each. $50 is not realistic here in so kal. Our weld shop rate is $95hr. For benchwork though, I think $65hr is fair.

Would probably need $2.5k maybe more after the first ten learning curve.

WSS

 

[PhulesAU]

Looks like you and the boy are having a great time. Have you tested for RFI?

 

[WSS]

Looks like you and the boy are having a great time. Have you tested for RFI?

Thank-you, we did have fun. We are headed to Northern Az tomorrow. We will bring it with us and he can play with the solar and charging ports. I suppose I should bring my EMF meter and see what the reality is. The antenna will always be mounted above 6' high, but a quick scan will let me know what the exposure is.

We are new to expedition style running but have been rock crawling and doing tough trails since he was born. This year I bought a F150 that he can drive. He has done well and I hope to let him get some wheel time this vacation off road. Our family Jeep has a SBC and a SM-420 trans, like shifting and driving a bus. It's just not a fun learner vehicle.

 

[Wildcat]

any experience with that shoemaker inverter? saw those at walmart and was thinking of trying one.

 

[Hillbilly Heaven]

Hey at least he gets to learn to stop and take off on an incline with both feet and he don't get to cheat and use the EBrake! Great father son project. He will never forget the time either. Project turned out looking great.

 

[WSS]

any experience with that shoemaker inverter? saw those at walmart and was thinking of trying one.

I have three of their battery chargers and never had a problem. My local hardware store (McFadden Dale ind. hardware) carries them, so i now have two inverters also, one hard mounted in my truck that is a 1000/1200w and now this 410w inverter. The chargers are pretty tough. I have one on wheels and two "smart" chargers that can charge UTV/garden AGM batts and regular lead acid batts automatically (even 6v). I rely on these to maintain the lesser used toys/off road vehicles. I assume the inverters are of the same quality.

 

[WSS]

Hey at least he gets to learn to stop and take off on an incline with both feet and he don't get to cheat and use the EBrake! Great father son project. He will never forget the time either. Project turned out looking great.

Haha!! Hey, I put a thumb throttle on my gear shift. It helps in those seat tearing situations. I think a person who learns on stick (or at least has one vehicle with stick) will have better instincts in bad or quick situations.

On his first go cart (chinese poo), the pedals were labeled "GO" for gas and "STOP" for brake. Luckily he could read words like these leaving kindergarten. Really funny because he treated them more like switches than variable pedals. It was hammer down on both pedals when needed.

 

[Hillbilly Heaven]

Thanks for reminding me that I need to get a PTO cable for my Bronco. I want to use it when running the On Board Air system. Also while the wife is comfortable driving a stick, it is those tricky situations that she gets nervous.

For those reading into this. No I do not have a PTO driven compressor it is engine driven but can use the pull type PTO cable to raise the RPM. If you read anything else in this shame on you! LOL